US6894419B2 - Current passing circuit board for rotary electric machine inserted in molded resin - Google Patents

Current passing circuit board for rotary electric machine inserted in molded resin Download PDF

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Publication number
US6894419B2
US6894419B2 US10/258,798 US25879802A US6894419B2 US 6894419 B2 US6894419 B2 US 6894419B2 US 25879802 A US25879802 A US 25879802A US 6894419 B2 US6894419 B2 US 6894419B2
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US
United States
Prior art keywords
current passing
circuit board
rotary electric
electric machine
metal plate
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Expired - Lifetime, expires
Application number
US10/258,798
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English (en)
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US20030076001A1 (en
Inventor
Youichi Fujita
Sotsuo Miyoshi
Satoru Hasegawa
Katsunori Takai
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Mitsubishi Electric Corp
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Mitsubishi Electric Corp
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Publication date
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Assigned to MITSUBISHI DENKI KABUSHIKI KAISHA reassignment MITSUBISHI DENKI KABUSHIKI KAISHA ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FUJITA, YOUICHI, HASEGAWA, SATORU, MIYOSHI, SOTSUO, TAKAI, KATSUNORI
Publication of US20030076001A1 publication Critical patent/US20030076001A1/en
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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/50—Fastening of winding heads, equalising connectors, or connections thereto
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K5/00—Casings; Enclosures; Supports
    • H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
    • H02K5/22—Auxiliary parts of casings not covered by groups H02K5/06-H02K5/20, e.g. shaped to form connection boxes or terminal boxes
    • H02K5/225—Terminal boxes or connection arrangements
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
    • H02K2203/03—Machines characterised by the wiring boards, i.e. printed circuit boards or similar structures for connecting the winding terminations

Definitions

  • the present invention relates to a current passing circuit board of a rotary electric machine for electrically connecting the winding terminals of stator coils of, for example, a DC motor, a generator or the like.
  • crossover wirings as connection means for electrically connecting the winding terminals of the respective stator coils thereof
  • a printed circuit board or a single pressed metal plate in place of the crossover wirings has been used so as to facilitate the connection work of winding terminals and to prevent a break in the connection portions of the winding terminals when the stator is molded.
  • FIGS. 1 ( a ) to ( c ) are developed perspective views to show the coil winding portions of stator coils in conventional DC motors in which winding patterns are different.
  • a reference numeral 1 denotes an annular yoke
  • a reference numeral 2 denotes a plurality of teeth disposed on the inner peripheral surface of the yoke 1
  • a reference numeral 3 denotes a terminal
  • a reference numeral 4 denotes windings wound around the above mentioned respective teeth 2 to constitute a plurality of stator coils.
  • the terminal portions of these windings 4 are connected to the respective stator coils by crossover wirings (not shown) to constitute the stators and the stators are molded with resin.
  • the windings 4 wound around the teeth 2 constitute three-phase stator coils of U-phase, V-phase, and W-phase
  • the terminal 3 is constituted by two terminals 3 a , 3 b for one tooth 2 .
  • a reference numeral 5 denotes a common wire-wound portion.
  • the present invention has been made to solve the above mentioned problems. It is the object of the present invention to provide a current passing circuit board of a rotary electric machine in which a plurality of wiring patterns that are complex and are to be electrically isolated from each other can be formed of a one metal plate and at the same time it eliminates the need for using a crossover wiring to thereby make a winding termination process easy, and it is easy to manufacture and can reduce the number of components and can reduce the manufacturing cost.
  • current passing patterns which are fundamentally to be electrically separated from each other are formed as one continuous current passing pattern that includes the unnecessary portions of the patterns, and the one continuous current passing pattern is molded with resin and the molded current passing pattern is pressed to punch out and eliminate the unnecessary portions of the above mentioned current passing pattern, thereby one current passing part can be produced in which the above mentioned one current passing pattern is separated into a plurality of current passing patterns.
  • the metal plate is provided with a portion where brush for contact is bonded.
  • the metal plate is provided with the current passing pattern for driving a brushless rotary electric machine.
  • the current passing circuit board of a rotary electric machine in accordance with the present invention is fixed to the side of the stator by swaging a protrusion formed on the side of the stator by an ultrasonic resin fusing method.
  • the current passing circuit board of a rotary electric machine in accordance with the present invention has a positioning portion by which it is mounted at the predetermined position of the stator.
  • FIG. 3 is a plan view to show a current passing circuit board constituted by molding the metal plate of resin which is shown in FIG. 2 .
  • FIG. 4 is a plan view of the current passing circuit board in FIG. 3 in a finished state.
  • FIG. 5 is a plan view of a state where the current passing circuit board in FIG. 4 is mounted with components.
  • FIG. 6 is a schematic cross sectional view of a DC motor.
  • FIGS. 7 ( a ) to ( c ) are explanatory views to show forming processes of a current passing circuit board of a rotary electric machine (brush motor) in accordance with a preferred embodiment 2 of the present invention.
  • FIGS. 8 ( a ) to ( c ) are explanatory views to show forming processes of a current passing circuit board of a rotary electric machine (brushless motor) in accordance with a preferred embodiment 3 of the present invention.
  • FIG. 9 is a cross sectional view to show a portion where a current passing circuit board of a rotary electric machine is mounted in accordance with a preferred embodiment 4 of the present invention.
  • FIG. 10 is a cross sectional view to show a portion where a current passing circuit board of a rotary electric machine is mounted in accordance with a preferred embodiment 5 of the present invention.
  • FIG. 11 is a schematic circuit diagram of a brush motor.
  • FIG. 12 is a schematic circuit diagram of a brushless motor.
  • FIG. 2 is a plan view of a metal plate constituting a current passing pattern of a current passing circuit board (current passing part) of a rotary electric machine in accordance with a preferred embodiment 1 of the present invention.
  • a reference numeral 10 denotes a metal plate made of a conducting material such as brass.
  • the metal plate 10 is formed in the shape of a predetermined pattern by pressing and, to be more specific, in the metal plate 10 , a nearly annular frame portion (formed frame) 11 , and a current passing pattern 12 and a crossover portion 13 , both of which are connected to the frame portion 11 , and a common wiring portion 14 , a brush setting portion 15 and a device mounting portion 16 are connected continuously to each other on a same plane. Further, a predetermined number of terminal portions 17 are bent at the predetermined portions of the frame portion 11 , the current passing pattern 12 and the crossover wiring portion 13 by the above mentioned pressing.
  • the integrally-structured current passing circuit board 21 of the molded resin 20 and the above mentioned metal plate 10 are constituted by molding the metal plate 10 , which is pressed in the shape of the pattern shown in FIG. 2 , of resin 20 .
  • a reference numeral 22 denotes a separating portion of the current passing pattern 12 formed of the metal plate 10
  • the separating portion 22 is to be a pattern cutting portion where the unnecessary portion of the above mentioned current passing pattern 12 is cut off and eliminated by pressing the current passing circuit board 21 as the finishing process of the current passing circuit board 21 .
  • the frame portion 11 of the metal plate 10 shown in FIG. 2 is also to be cut off and eliminated by the finish pressing of the above mentioned current passing circuit board 21 . Therefore, the unnecessary portions of the current passing patterns 12 shown in FIG. 2 are cut off and eliminated by the finish pressing of the current passing bond 21 to constitute an essential isolated pattern in which the respective current passing patterns 12 are electrically isolated from each other and the respective crossover wiring portions 13 are also independent of each other.
  • the plurality of isolated current passing patterns 12 and the plurality of isolated crossover wiring portions 13 are integrally bonded to each other in advance by the molded resin 20 , so that they don't come apart.
  • FIG. 5 is a plan view of a state where the current passing circuit board in FIG. 4 is mounted with components.
  • the current passing circuit board 21 as one current passing part that has the plurality of isolated current passing patterns 12 , the plurality of isolated crossover wiring portions 13 and the common wiring 14 , is constituted by mounting respectively on the predetermined points of the metal plate 10 of the current passing circuit board 21 that is finished, as shown in FIG. 4 , the plurality of devices 25 and the plate spring 23 to which the brush 24 is bonded.
  • FIG. 6 is a schematic cross sectional view of the DC motor.
  • one current passing part 21 is formed of the metal plate 10 in which the current passing patterns 12 those are essentially to be isolated from each other, are continuously formed, and the molded resin 20 into which the metal plate 10 is inserted, and the integrally formed combination of the metal plate 10 and the molded resin 20 is pressed to cut off and eliminate the unnecessary portions of the above mentioned current passing patterns 12 thereby to form the one current passing part 21 that has the plurality of isolated current passing patterns 12 each having a normal shape on the same plane.
  • crossover wiring portion 13 is also formed by the above mentioned metal plate 10 , it is possible to produce an effect of eliminating the need for providing a different crossover wiring for terminating the windings of the respective stator coils in the prior art and easily terminating the wiring terminals extended vertically from the respective stator coils only by connecting the wiring terminals to the current passing part.
  • the different crossover wiring is not required as described above, so that it is possible to produce an effect of winding the wirings independently around the respective teeth and easily winding the wirings.
  • the above mentioned current passing part 21 applied to a DC brush motor is provided with the brush setting portion 15 and the device mounting portion 16 , if a conducting plate spring 23 having a brush 24 for contact at the tip thereof is bonded to the above mentioned brush setting portion 15 and a device 25 for preventing noises is bonded to the device mounting portion 16 to realize a unitization to the one current passing part 21 , it is possible to produce an effect of reducing the number of components and at the same time of mounting the components on the motor case 31 with ease.
  • FIGS. 7 ( a ) to ( c ) are explanatory views to show the forming processes of the current passing circuit board of a rotary electric machine (brush motor) in accordance with a preferred embodiment 2 of the present invention.
  • the same reference numbers are attached to portions equal to or corresponding to those in FIG. 2 to FIG. 5 .
  • the metal plate 10 forms the current passing pattern 12 for driving a three-terminal brush motor, and the current passing pattern 12 has the brush setting portion 15 and the device mounting portion 16 , in which a portion of the current passing pattern 12 and the device mounting portion 16 are continuously and integrally with the formed frame 11 formed in the shape of a rectangle in one plane.
  • the portions other than the formed frame 11 of the above mentioned metal plate 10 are molded with resin to form the metal plate 10 into the state where the current passing pattern 12 and the device mounting portion 16 are inserted into the molded resin 20 , as shown in FIG. 7 ( b ).
  • FIGS. 8 ( a ) to ( c ) are explanatory views to show the forming processes of the current passing circuit board of a rotary electric machine (brushless motor) in accordance with a preferred embodiment 3 of the present invention.
  • the same reference numerals are attached to portions equal to or corresponding to those in FIG. 2 to FIG. 5 .
  • a reference character 31 a denotes a protrusion for mounting a current passing circuit board, which is formed integrally in the protruding manner at an opening end portion on the commutator 38 side of the motor case 31 in FIG. 6
  • a reference character 21 a denotes a mounting hole made in the current passing circuit board 21
  • the mounting position of the current passing circuit board 21 is determined by fitting the above mentioned protrusion 31 a in the mounting hole 21 a . Then, the head portion of the above mentioned protrusion 31 a is swaged in this positioned state by an ultrasonic resin fusing method to mount and fix the current passing circuit board 21 to the above mentioned motor case 31 .
  • a reference numeral 40 denotes a sensor case that has a built-in sensor and that is mounted on the opening end portion on the commutator 38 side of the motor case 31 , and the current passing circuit board 21 is mounted by means of the sensor case 40 .
  • the current passing circuit board of a rotary electric machine in accordance with the present invention can connect the windings of the respective stator coils of the rotary electric machine such as various kinds of motors, generators and the like without using the crossover wirings and thus can reduce the number of components and can reduce manufacturing cost.
  • the current passing circuit board does not need the crossover wirings, the current passing circuit board is suitable to prevent a break in wiring and to improve reliability.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacture Of Motors, Generators (AREA)
  • Brushless Motors (AREA)
  • Motor Or Generator Frames (AREA)
US10/258,798 2001-02-28 2001-02-28 Current passing circuit board for rotary electric machine inserted in molded resin Expired - Lifetime US6894419B2 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/JP2001/001526 WO2002069477A1 (fr) 2001-02-28 2001-02-28 Substrat d'excitation de machine electrique rotative

Publications (2)

Publication Number Publication Date
US20030076001A1 US20030076001A1 (en) 2003-04-24
US6894419B2 true US6894419B2 (en) 2005-05-17

Family

ID=11737077

Family Applications (1)

Application Number Title Priority Date Filing Date
US10/258,798 Expired - Lifetime US6894419B2 (en) 2001-02-28 2001-02-28 Current passing circuit board for rotary electric machine inserted in molded resin

Country Status (7)

Country Link
US (1) US6894419B2 (de)
EP (1) EP1280258B1 (de)
JP (1) JP4294320B2 (de)
KR (1) KR100652177B1 (de)
CN (1) CN1253992C (de)
DE (1) DE60131741T2 (de)
WO (1) WO2002069477A1 (de)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7808137B2 (en) 2006-10-05 2010-10-05 Remy Technologies, L.L.C. Single track layer stator terminal assembly
JP2011151875A (ja) * 2010-01-19 2011-08-04 Panasonic Corp 同期回転機の固定子

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US3602793A (en) * 1969-03-29 1971-08-31 Bosch Gmbh Robert Rectifier housing unit having adjacent parallel oppositely-biased cooling plates
US3604963A (en) * 1969-11-26 1971-09-14 Nippon Denso Co Prefabricated connector plate for use with a plurality of different ac to dc generator circuits
US3641374A (en) * 1970-03-11 1972-02-08 Nippon Denso Co Rectifying means for three-phase alternating generators for use in vehicles and other transport facilities
US3777193A (en) * 1972-02-24 1973-12-04 Siemens Ag Rectifier bridge assembly
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US4232238A (en) * 1978-03-06 1980-11-04 Hitachi, Ltd. Rectifier assembly for AC generators for use with vehicles
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JPH04140054A (ja) 1990-09-29 1992-05-14 Matsushita Electric Works Ltd ブラシレスモーター
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US5530311A (en) * 1994-05-24 1996-06-25 Mccord Winn Textron, Inc. Face type commutator with sideways tangs and a method of making the commutator
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US6584673B2 (en) * 2000-07-31 2003-07-01 Mccord Winn Textron Inc. Planar commutator segment attachment method and assembly
US6661134B2 (en) * 2000-12-18 2003-12-09 Calsonic Kansei Corporation Brushless motor
US6664676B1 (en) * 1999-12-10 2003-12-16 Matsushita Electric Industrial Co., Ltd. Motor assembled by using motor-base-holder and method of assembling the same motor
US6674212B2 (en) * 2001-06-05 2004-01-06 Denso Corporation Current-carrying member for a direct-current motor in a fuel pump, method for producing the same, and fuel pump
US6684485B1 (en) * 1999-06-02 2004-02-03 Kolektor D.O.O. Method of producing a flat commutator and a flat commutator produced according to said method
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US6836050B2 (en) * 2001-11-05 2004-12-28 Sankyo Seiki Mfg. Co., Ltd. Terminal structures for motor with brush to connect motor to external circuit

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3602793A (en) * 1969-03-29 1971-08-31 Bosch Gmbh Robert Rectifier housing unit having adjacent parallel oppositely-biased cooling plates
US3573516A (en) * 1969-04-23 1971-04-06 Gen Electric Rectifier bridge for use with an alternator
US3604963A (en) * 1969-11-26 1971-09-14 Nippon Denso Co Prefabricated connector plate for use with a plurality of different ac to dc generator circuits
US3641374A (en) * 1970-03-11 1972-02-08 Nippon Denso Co Rectifying means for three-phase alternating generators for use in vehicles and other transport facilities
US3789275A (en) * 1971-09-30 1974-01-29 Tokyo Shibaura Electric Co Alternator rectifier assemblies with resinous molded member containing circuit pattern molded therein
US3777193A (en) * 1972-02-24 1973-12-04 Siemens Ag Rectifier bridge assembly
US4232238A (en) * 1978-03-06 1980-11-04 Hitachi, Ltd. Rectifier assembly for AC generators for use with vehicles
US4604643A (en) * 1980-09-04 1986-08-05 Tokyo Shibaura Denki Kabushiki Kaisha Semiconductor rectifier device
US5013948A (en) * 1987-05-04 1991-05-07 Allied-Signal Inc. High power rotating rectifier assembly
US4952829A (en) 1987-08-22 1990-08-28 Robert Bosch Gmbh Rectifier arrangement
US4926078A (en) * 1988-04-21 1990-05-15 Mitsubishi Denki Kabushiki Kaisha Brush and terminal assembly for engine starter
JPH04140054A (ja) 1990-09-29 1992-05-14 Matsushita Electric Works Ltd ブラシレスモーター
EP0501787A2 (de) * 1991-02-28 1992-09-02 Hitachi, Ltd. Gleitender Stromabnehmer aus Keramik
US5712517A (en) * 1992-09-15 1998-01-27 Ford Motor Company Epoxy insulator coating on an alternator heat sink
US5677588A (en) * 1994-02-12 1997-10-14 Johnson Electric S.A. Planar carbon segment commutator
US5530311A (en) * 1994-05-24 1996-06-25 Mccord Winn Textron, Inc. Face type commutator with sideways tangs and a method of making the commutator
US5682070A (en) * 1995-06-28 1997-10-28 Mitsubishi Denki Kabushiki Kaisha Vehicle-mounted alternator
US5996210A (en) * 1995-07-13 1999-12-07 Kautt & Bux Commutator Gmbh Method of producing a flat commutator
US5962946A (en) * 1995-12-19 1999-10-05 Walbro Corporation Method of making a flat commutator
US5793140A (en) * 1995-12-19 1998-08-11 Walbro Corporation Electric motor flat commutator
US5760518A (en) * 1995-12-29 1998-06-02 Aupac Co., Ltd. Flat-type commutator and method for its manufacture
JPH09322459A (ja) 1996-05-31 1997-12-12 Hitachi Ltd モータ及びモータの固定子コイル端末線接続方法
JPH10174340A (ja) 1996-12-10 1998-06-26 Shibaura Eng Works Co Ltd モータ
DE19705833A1 (de) 1997-02-15 1998-08-20 Itt Mfg Enterprises Inc Bürstenhalteanordnung
US6222298B1 (en) * 1997-06-08 2001-04-24 Mitsuba Corporation Carbon commutator and method for producing the same
US6490780B1 (en) * 1998-11-11 2002-12-10 Samsung Electronics Co., Ltd. Method for making a commutator
US6515398B1 (en) * 1999-02-04 2003-02-04 Denso Corporation Alternator having passage for ventilating slip-ring surface
US6684485B1 (en) * 1999-06-02 2004-02-03 Kolektor D.O.O. Method of producing a flat commutator and a flat commutator produced according to said method
US6664676B1 (en) * 1999-12-10 2003-12-16 Matsushita Electric Industrial Co., Ltd. Motor assembled by using motor-base-holder and method of assembling the same motor
US6584673B2 (en) * 2000-07-31 2003-07-01 Mccord Winn Textron Inc. Planar commutator segment attachment method and assembly
US6737772B2 (en) * 2000-10-18 2004-05-18 Mitsubishi Denki Kabushiki Kaisha AC generator for use in vehicle and method for forming connection latch portion in conductor wire applied to stator winding thereof
US6661134B2 (en) * 2000-12-18 2003-12-09 Calsonic Kansei Corporation Brushless motor
US6674212B2 (en) * 2001-06-05 2004-01-06 Denso Corporation Current-carrying member for a direct-current motor in a fuel pump, method for producing the same, and fuel pump
US6836050B2 (en) * 2001-11-05 2004-12-28 Sankyo Seiki Mfg. Co., Ltd. Terminal structures for motor with brush to connect motor to external circuit

Also Published As

Publication number Publication date
US20030076001A1 (en) 2003-04-24
KR20020089531A (ko) 2002-11-29
JP4294320B2 (ja) 2009-07-08
KR100652177B1 (ko) 2006-11-29
CN1253992C (zh) 2006-04-26
JPWO2002069477A1 (ja) 2004-07-02
EP1280258A1 (de) 2003-01-29
DE60131741T2 (de) 2008-11-06
DE60131741D1 (de) 2008-01-17
EP1280258B1 (de) 2007-12-05
EP1280258A4 (de) 2003-09-10
WO2002069477A1 (fr) 2002-09-06
CN1426624A (zh) 2003-06-25

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